KR100768976B1 - Manufacturing method of thin-film electrochemical unit cell - Google Patents

Abstract

An apparatus and method provides for rotatably cutting and/or laminating layered structures or sheet material supported by webs. A rotary converting apparatus and method of the present invention converts a web comprising a cathode layered structure and a web comprising an anode layered structure into a series of layered electrochemical cell structures supported by a release liner. Employment of a rotary converting process of the present invention provides, among other benefits, for the creation of a product having a finished size, without need for downstream or subsequent cutting.

Description

Manufacturing method of thin-film electrochemical unit cell {MANUFACTURING METHOD OF THIN-FILM ELECTROCHEMICAL UNIT CELL}

TECHNICAL FIELD The present invention generally relates to lamination apparatus and methods, and more particularly, to rotation conversion lamination apparatus and methods.

Several lamination apparatuses and methods have been developed for producing products made of sheet materials. Many conventional lamination methods utilize a cutting mechanism that cuts the sheet material into small segments. The individual segments are then aligned and stacked either manually or mechanically in part of an independent lamination process. The laminate structure is then subjected to the lamination force by a mechanism that creates an appropriate force.

Although various conventional lamination and loading methods are widely used, many such methods are not well suited for applications requiring a relatively high level of productivity, automation and flexibility. For example, many conventional lamination methods cannot accommodate various kinds of materials, sheet sizes and sheet shapes. Many such conventional lamination methods are not well suited for automatically and continuously laminating, for example, lamination webs of various materials typically required in the construction of thin film electrochemical lamination structures.

There is a need for improved apparatus and methods for laminating films and sheet materials of various types, colors, shapes and sizes. In particular, there is a need for improved apparatus and methods for manufacturing electrochemical unit cells for use in the construction of solid state thin film batteries and for stacking layers of electrochemical cell materials. The present invention satisfies this need and the like.

The present invention generally relates to apparatus and methods for rotatably cutting and / or laminating sheet material or laminate structures supported by a web. In addition, the present invention is an apparatus for rotatably cutting a laminated structure or sheet material supported by a web, and laminating the cut laminate structure / sheet to another web material to provide space between adjacent cut laminate structures / sheets. And to a method. A further feature of the structure and process of the present invention is that within the space between the adjacent adjacent stacked structures / sheets, one web material is cut through completely while only a portion of the liner of the other web is cut.

In connection with the electrochemical cell configuration, the rotation conversion device and method of the present invention comprises a web comprising an anode laminated structure and a web comprising a cathode laminated structure into a series of stacked electrochemical cell structures supported by a release liner. Convert. Using the rotation conversion process of the present invention, the advantage is that a product having a final size can be formed without the need for downstream (or subsequent) cutting steps.

According to one embodiment of the present invention, an apparatus and method are provided for the manufacture of a series of thin film electrochemical unit cells. A web (cathode web) comprising a cathode laminate structure moving at a first speed is cut into a series of cathode sheets. Each cathode sheet is moved at a second speed equal to or faster than the first speed. Each cathode sheet moving at a second speed is laminated to a web (anode web) comprising an anode stack structure moving at a second speed to produce a stacked unit cell having a space between adjacent cathode sheets. The stacked anode web is cut in the space between adjacent cathode sheets to produce a series of unit cell sheets.

In one particular embodiment, cutting the cathode web includes cutting a portion of the cathode web and removing excess cathode web. In this embodiment, the space between adjacent cathode sheets is a function of the size and / or shape of the excess cathode web removed.

According to yet another embodiment, cutting the cathode web comprises rotatably cutting the cathode web, and laminating each cathode sheet on the anode web is rotatable each cathode sheet at a second speed. And moving to make it easier. Laying each cathode sheet to the anode web may further comprise rotatably moving the anode web at a second speed. The anode web may include a release liner, and cutting the laminated anode web may include cutting through the anode laminate structure to the release liner (or only a portion of the release liner).

Each anode sheet may be defined by the length (L). Cutting the cathode web may be accomplished using a rotating die. In this case, the length L of each cathode sheet is a function of the first speed W1 of cathode web movement relative to the second speed W2 of the rotating die.

The cathode web may be cut using one or more rotating die blades spaced at circumferential blade spacing D. FIG. In this case, the length L of each cathode sheet is a function of the first speed W1 of cathode web movement and the second speed W2 of the rotating die with respect to the circumferential die blade spacing D. For example, the length L of each cathode sheet may be determined by the formula L = D (W1 / W2).

According to one embodiment, the space S between adjacent cathode sheets is a function of the first velocity W1 of the cathode web movement relative to the second velocity W2 of the anode web movement. Cutting the cathode web may include cutting the cathode web using one or more rotating die blades spaced at circumferential blade spacing D, thus providing space S between adjacent cathode sheets. Is a function of the first speed W1 of the cathode web movement and the second speed W2 of the rotating die with respect to the circumferential die blade spacing D. For example, the space S between adjacent cathode sheets may be determined by the formula S = D ((W2 / W1) -1).

According to another embodiment of the present invention, the cathode sheet may be defined by a length L between about 0.25 inches (about 0.635 cm) and about 24 inches (about 60.96 cm). The space S between adjacent cathode sheets may be between about 0.015 inches (about 0.038 cm) and about 0.4 inches (about 1.016 cm). The ratio of the second speed to the first speed may be between about 1.005 and about 1.05. The first speed may be between about 5 feet per minute (about 1.524 m) to about 500 feet per minute (about 152.4 m), and the second speed may be between about 5.025 feet per minute (about 1.532 m) to about 525 feet per minute (about 160.02 m). )

Laminating the cathode sheet to the anode web includes laminating each cathode sheet to the anode web such that a portion of each cathode sheet extends beyond at least one edge of the anode stack structure of the anode web to provide a stack offset therebetween. The step may further include a stack offset, for example, between about 0.04 inches (about 0.102 cm) and about 0.31 inches (about 0.787 cm).

Laminating each cathode sheet to the anode web may further comprise heating either or both of the anode web or cathode sheet. Cutting the laminated anode web may include detecting the space between adjacent cathode sheets, for example by light or mechanical techniques.

According to another embodiment of the present invention, an apparatus and method for manufacturing a series of thin film electrochemical unit cells includes moving a web (cathode web) that includes a cathode stack structure at a first speed. The cathode web is rotatably cut at a second speed to produce a series of cathode sheets. In order to produce a stacked unit cell having a space between adjacent cathode sheets, each cathode sheet moving at a second speed is rotatably in a web (anode web) comprising an anode stack structure moving at a third speed. Laminated.

In one configuration, the first speed, the second speed, and the third speed are substantially the same. In another configuration, the second speed and the third speed are substantially the same, and the second speed and the third speed are faster than the first speed. In another configuration, the first speed and the second speed are substantially the same, and the third speed is faster than the first speed and the second speed. In another configuration, the first speed, the second speed, and the third speed are not the same, the third speed is faster than the second speed, and the third speed and the second speed are faster than the first speed.

According to another configuration, the first speed and the second speed are substantially the same, and cutting the cathode web comprises cutting a portion of the cathode web and removing excess cathode web to make space between adjacent cathode sheets. Steps. In this case, the space between adjacent sheets is a function of the shape and / or size of the excess cathode web removed.

In another method, the third speed is faster than the first speed and the second speed, and the step of laminating each cathode sheet to the anode web moves the anode web at a third speed to make space between adjacent cathode sheets. It further comprises a step. According to another method, the third speed is faster than the first speed and the second speed, and the step of laminating each cathode sheet on the anode web comprises each cathode sheet at a second speed to make space between adjacent cathode sheets. And rotatably moving the anode web at a third speed while rotatably moving. Laminating each cathode sheet to the anode web comprises: each cathode sheet to the anode web such that a portion of each cathode sheet extends past at least one edge of the anode stack structure of the anode web to provide a stack offset therebetween. It may further comprise the step of laminating.

According to another embodiment of the present invention, an apparatus and method for manufacturing a series of thin film electrochemical unit cells uses a rotating die having a pattern to produce a series of cathode stacked structures at a first speed through a web comprising the cathode stacked structures. Cutting to In order to fabricate stacked unit cells having spaces between adjacent cathode stacks, each cathode stack is laminated to a web comprising an anode stack that moves at a second speed equal to or faster than the first speed. Waste cathode web material resulting from cutting by a rotating die having a pattern is discarded or collected.

According to this embodiment, the space between adjacent cathode stack structures is a function of the size and / or shape of the rotating die having the pattern. The rotary die with a pattern may have a rectangular shape, for example.

According to another embodiment, the outlet of the rotation converter of the present invention may be coupled to the inlet of the loading device of the present invention. The rotational transformation / loading apparatus and method combined in accordance with the present invention produce a stacked stack of similar or dissimilar layers of various materials having virtually any shape.

The foregoing summary of the present invention does not describe all embodiments of the present invention. With the fuller understanding of the present invention, the advantages and effects of the present invention will become apparent by reference to the following detailed description and claims taken in conjunction with the accompanying drawings.

1 illustrates a rotation converting and stacking device according to an embodiment of the present invention.

FIG. 2 is a subassembly of FIG. 1 showing a rotation converter according to an embodiment of the present invention. FIG.

FIG. 3A is a subassembly of FIG. 2, which is a detailed view of the first rotational cut / laminate contact area of the rotation converter in accordance with one embodiment of the present invention.

FIG. 3B shows the cutting cathode sheet moving on the anvil in the first rotary cutting / lamination contact region shown in FIG. 3A.

3C-3F show four embodiments of a rotation converter including a feed, a cut and a stack, each of which can operate at the same or different processing speeds.

4 is a subassembly of FIG. 2, which is a detailed illustration of a second rotational cutting contact region of a rotational conversion device according to one embodiment of the invention.

FIG. 5 is a detailed view of the second rotary cut contact region shown in FIG. 4. FIG.

6 is a subassembly of FIG. 1 illustrating a loading device according to an embodiment of the present invention.

7A and 7B illustrate a portion of a loading apparatus according to one embodiment of the present invention.

8 illustrates a loading apparatus according to another embodiment of the present invention.

9 illustrates a multi-station, single product web loading apparatus in accordance with an embodiment of the present invention.                 

Figure 10 illustrates a single station, single product web loading apparatus in accordance with one embodiment of the present invention.

Figure 11 illustrates a multi station, multi product web loading apparatus in accordance with an embodiment of the present invention.

12A and 12B illustrate a rotation conversion / lamination apparatus according to another embodiment of the present invention.

Figure 13 illustrates a lamination stack of multicolor sheet material produced by a rotation conversion and / or stacking device in accordance with the principles of the present invention.

Figure 14 illustrates a multi-layered single colored paper or film sheet having a portion of the back side having an adhesive laminated together and cut into a predetermined shape using a rotation conversion and / or stacking device in accordance with the principles of the present invention.

FIG. 15 shows a multi-layered single color paper or film sheet having a shape different from that shown in FIG. 14 but similar to that shown in FIG.

Figure 16 illustrates a product stack or pad comprising several sheets or film layers of varying shapes and sizes made by a rotation conversion and / or stacking device in accordance with the principles of the present invention.

Figure 17 shows a product stack comprising several sheets or film layers, each sheet having a different shape made by a rotation conversion and / or stacking device in accordance with the principles of the present invention.

Figure 18 illustrates a pack of medical dressings made by a rotational conversion and / or loading device in accordance with the principles of the present invention.

While the invention is susceptible to various modifications and alternative forms, specifics thereof have been illustrated in the drawings and will be described in detail below. However, it should be understood that the invention is not limited to the specific embodiments described. Rather, the invention includes all modifications, equivalents and alternatives falling within the scope of the invention as defined by the appended claims.

DETAILED DESCRIPTION In the following description of embodiments, reference is made to the accompanying drawings that illustrate various embodiments in which the invention may be practiced. Structural changes may be made and embodiments may be used without departing from the scope of the invention.

Preferably, the rotation conversion lamination and stacking apparatus of the present invention is provided for the production of a stacked stack of similar or dissimilar layers of various materials in any shape. The principles of the present invention may be applied to produce a product of laminated stacks from a single product web or multiple product webs (eg, five different product webs). Laminated stacks of articles made according to the invention may comprise pads of single or multicolored sheets or films, for example, packs of thin film batteries and medical dressings.

One particular use relates to the manufacture of electrochemical battery cells in which complex alternating layers of cathode, separator and anode materials are cut and stacked into stacks or unit cells. In the field of this invention, a manufacturable thin film electrochemical unit cell may be defined as a stack subassembly comprising a minimum sheet of this sequence typical of current collectors, cathodes, separators and anodes. For example, by providing two or more rotational conversion stations upstream of the loading apparatus, the cathode and anode layers may be cut independently, which is important in preventing short circuits between the unit cell anode and the cathode structure.

Depending on the relative position of the separator and the choice of machining and timing, the respective zones of the cathode, anode and separator can be determined independently. This is important to maintain a constant current distribution that is important for electrochemical cell life. For example, by sizing the separator faster than the cutting cathode, macroscopic shorts caused by edge burrs are avoided. This can eliminate the auxiliary insulators that may be required between the electrodes in the design of some cells.

These principles can also be applied to fuel cell structures. In addition, these principles may be used to manufacture new packaged medical products where only one packaging layer is used per product layer and the final product is converted, loaded and delivered to the customer in packaged form. For example, the first and last layers disposed on the stack may be outer packages.

Referring now to the drawings, an apparatus 10 for producing a series of electrochemical cell sheets using a web of cathode material and anode material to produce a stack of electrochemical cell layers is shown in FIG. Apparatus 10 represents two processing apparatuses 20 and 120, referred to as rotation converter 20 and stacking apparatus 120, respectively. In one embodiment, the device 10 is a flat and relatively inert of electrochemical cell material layers, which may or may not include low soft layers, from a relatively flexible material supported by a release liner. Provided is a continuous motion assembly process for manufacturing adult multilayer stacks. An advantage of the present invention is that it is possible to load multi-layer assemblies containing no layers or containing many layers of low soft material. In this regard, the loading process of the present invention accommodates the stretching properties of the layers in the product, which can vary greatly between the products.

The rotational conversion device and the loading device 20,120 may individually combine a number of unique and useful features so that these devices and associated processing methods may be used separately, as shown in FIG. It does not necessarily need to be combined as. As described below, the rotation converter 20, which can be used in various ways, may be used independently to produce a series of stacked unit cell structures that are typically supported by a release liner. Loading device 120, which may be implemented in a variety of ways, may be used independently to fabricate a stack of electrochemical cell layers using continuous operation loading operations. Examples of loading devices and methods are described in co-pending US patent application Ser. No. 09 / 718,549, commonly referred to as Agent Document No. 810.509US01 (55530USA6A), entitled "Loading Devices and Methods for Laminated Products and Packages." The entirety of which is hereby incorporated by reference.

The commercially available rotation converter 20 converts the cathode web 23 and the anode web 123 into a series of layered electrochemical cell structures supported by a release liner. The loading device 120 allows for the continuous loading of electrochemical cell structures transferred from the peelable liner to a number of recirculating, circulating or reciprocating platforms (also referred to as puck, pallet or carriage). to provide. One advantage obtained by using the rotation conversion process of the present invention is that it forms a product having a final size without the need for downstream or subsequent cutting.

In one embodiment, layered electrochemical cell structures generally comprise an anode stack and a cathode stack with one or more solid electrolyte layers combined. Such a structure is referred to hereinafter as a unit cell, and the configuration is as described above.

The cathode stack structure may be defined as a subassembly comprising a cathode, a current collector, a cathode. Another configuration of the cathode stack structure subassembly includes a separator, a cathode, a current collector, and a cathode. Another cathode stack structure subassembly configuration includes a separator, a cathode, a current collector, a cathode, a separator.

The anode laminate structure may be defined as a separate anode sheet. The anode stack structure may also be defined as a subassembly comprising an anode and a separator. Another configuration of the anode stack structure subassembly includes a separator, an anode, and a separator.

For example, cathode web 23 may be fabricated to include an aluminum foil current collector coated on both sides with a composite cathode material (cathode / current collector / cathode structure). The anode web 123 may be manufactured, for example, as a four layer structure, which includes a peelable liner, a solid electrolyte film, a lithium foil, and a second solid electrolyte film layer (separator / anode / separator structure). . In one particular embodiment, a solid polymer electrolyte film is used in the anode web 123.

According to another embodiment, cathode web 23 may include a separator, such as a solid polymer electrolyte film, on both sides of the composite cathode material. In yet another embodiment, the separator may be included in each of the cathode web and the anode web 23, 123. Other multilayer cathode, anode and solid electrolyte web structures may also be considered.

According to one embodiment, the webs 23 and 123 can be moved at a speed between 0 and 10 m / min. The width of the product web may be about 8 inches (about 20.32 cm). The unit cell sheet may have a length of up to about 17 inches (about 43.18 cm). The product web feed rolls can each have a diameter of up to about 18 inches (about 45.72 cm).

Referring now to FIG. 2, a rotation conversion device 20 according to one embodiment of the present invention is shown in more detail. The rotation converter 20 shown in FIG. 2 comprises a web 23 of cathode material initially wound on a cathode feed roll 22. Upon winding, the cathode web may include a release liner 21 wound over the liner take-up roll 24 while the cathode feed roll 22 is unwound. The cathode web 23 without the release liner 21 is fed to the first cutting station 28. The cathode web 23 generally passes through a tension roll device 26, which brings the cathode web 23 into the desired tension state, and may include a web guiding mechanism.

In the embodiment shown in Figure 2, the first cutting station 28 represents a rotating die station. The first cutting station 28 comprises a driven traction roll device 31, in which case the driven traction roll device 31 comprises a nip roll 32 and a rubber-coated drive roll 33. Alternatively, a vacuum pull roll device may be used. Movements such as speed and / or acceleration of the pull roll device 31 are generally controlled by a servo control system (not shown), as is known. The pull roll device 31 supplies the cathode web 23 to the cutting roll device 30, which includes a rotating die 34 and an anvil 35. The cutting roll device 30 cuts the cathode web 23 into individual cathode sheets. Movements such as the speed and / or acceleration of the rotary die 34 and the anvil 35 are generally controlled by a servo control system (not shown).

As also shown in FIG. 2, the web 123 of anode material is fed to the stacking apparatus 29. The anode web 123 may also be heated by an infrared heater 38 (shown in dashed lines) in the first cutting station 28 or before entering the first delivery station 28. As noted above, anode web 123 generally includes a peelable liner and may include two solid electrolyte layers (also referred to as separator layers) provided on either side of the anode (eg, lithium foil). have. The anode web 123 is generally tensioned and guided to the desired extent by the tension roll device 39.

The cathode sheets are rotated by the anvil 35 in proximity to the anode web 123 in the lamination apparatus 29. The cathode sheets are laminated to the anode web 123 in a nip formed between the lamination roll 36 and the anvil 35 to form a lamination web 50 of unit cell material. The lamination roll 36 is generally coated with a rubber material, and the anvil 35 is generally made of a metal material.

According to one embodiment of the present invention, the anode web 123 passes through the stacking apparatus 29 at a faster speed than the cathode web 23. Due to the difference in the relative speeds of the anode web 123 and the cathode web 23, a space is formed between the cathode sheets when each cathode sheet is laminated to the anode web 123. The laminated web 50 of unit cell material is fed from the first cutting station 28 to the second cutting station 40, at which the anode web material is cut through but the release liner is penetrated. It is not cut.

In the second cutting station 40, the driven nip roll 42 and the rubber-coated drive roll 43 drive the lamination web 50, including the rotating die 44 and the anvil 45. Transfer to). The rotating die 44 cooperating with the anvil 45 cuts through the anode material of the laminated web 50 in the space formed between adjacent cathode sheets but does not cut through the release liner. Nip roll 42 may be heated. An optical sensor 37 is used to detect the space between adjacent cathode sheets to ensure that the cut in the laminated web 50 is made only within the space described above. Aligning the space or gap between cathode sheets adjacent to the appropriate cutting position in the second cutting station 40 may be made using appropriate timing, gears and / or belts without light or other gap detection or detection. It should be noted that

Thus, a series of stacked unit cell sheets supported on a release liner is produced at the exit of the second cutting station 40. The stacked unit cell sheets may be transferred directly to a loading device, which is part of a continuous rotation conversion / loading operation, for example as shown in FIG. 1, or wound on a winding roll for subsequent processing by the loading device. .

The advantage obtained by using the rotation converter of the present invention is that the electrochemical generator can be assembled from individual sheets of anode web and cathode web material in which the anode sheet and the cathode sheet are cut independently of each other, so that the cutting step To prevent potential short circuits from occurring. Due to the space formed between adjacent cathode sheets, the cathode web 23 can be cut into cathode sheets regardless of the cutting of the anode web 123. More specifically, cathode web 23 is cut into cathode sheets at first cutting station 28 before being laminated to faster anode web 123. The spaces formed before the lamination apparatus 29 are for cutting through only the anode web material at the second cutting station 40.

Another advantage is that the cathode sheet and the anode sheet can be cut independently as described above, and also the cathode sheets can be laminated at a crossweb offset relative to the anode sheet, whereby the lamination offset between them To form. The unit cell sheet constructed in this way comprises, for example, a laminated structure of separator / anode / separator extending past all four edges of the cathode coating. A current collector that extends beyond one edge of the stack of separator / anode / separator supports the cathode coating. According to this embodiment, it should be noted that the two webs are multilayer and not all layers need to have the same width. This unit cell sheet structure provides several advantages, such as preventing subsequent loading and associated cutting operations and short-circuits during cell assembly or finishing, and improves manufacturing capability.

Other unit cell sheet configurations can be obtained by appropriately sizing the various material layers included in each cathode web and anode web 23, 123. The anode web 123 conveyed to the stacking device 29 has a liner / with a first edge where the edges of the separator layer extend to the edge of the lithium foil and a second edge where the lithium foil extends beyond the edge of the separator layers. It may also be configured as a separator / lithium foil / separator structure. Therefore, the unit cell sheet structure may be formed such that the lengths of the cathode and current collector layers are shorter than the anode layers.

3A and 3B illustrate various aspects of the first cutting station 28 shown in FIGS. 1 and 2 in more detail. According to one embodiment, the cathode web 23 is moved to the cutting roll device 30 at a speed W1 by the pull roll device 31. The cutting roll device 30 shown as including the rotary die 34 and the anvil 35 is controlled to move at a speed W2 faster than the speed W1 of the cathode web 23.

The die blade 47 provided on the rotating die 34 cooperating with the anvil 35 is cut through the cathode web 23, thereby showing the individual cathode sheet 52 (shown in more detail in FIG. 3B). To make them). The rotary die 34 may include a single die blade 47, a double die blade 47 as shown in FIG. 3A, or two or more die blades 47. In addition, die blade 47 may be a single blade or have a more complex blade configuration. For example, a rectangular die blade configuration or pattern may be provided over the rotary die 34. Other methods and apparatus for cutting or stamping the cathode web 23 may be used depending on the system in which it is implemented, for example using a shearing device, a laser, or a water jet.

In one embodiment, the anvil 35 is a vacuum anvil roll with a hole spacing pattern that matches the seat die blade space. The individual cathode sheets 52 whose moving speed changes from the speed W1 of the cathode web 23 to the speed W2 are then transferred to the lamination apparatus 29.

Anvil 35, lamination roll 36, and anode web 123 of lamination apparatus 29 move at speed W2. In addition, the individual cathode sheets 52 moving at the speed W2 are laminated to the anode web 123 in a nip formed between the rubber coated lamination roll 36 and the anvil 35. The difference between the speed W2 and the speed W1 faster than the speed W1 forms a space 53 between adjacent cathode sheets during the lamination process. Laminated web 50 supported by the release liner of anode web 123 is then transferred to second cutting station 40.

For most applications, an appropriate speed ratio (ie, W2 / W1) of the faster moving anode web 123 to the slower moving cathode web 23 may vary between about 1.005 and about 1.05. For example, the speed W1 of the cathode web 23 may be between about 5 feet per minute (fpm) (about 1.524 m / min) to about 500 fpm (about 152.4 m / min), and the speed of the anode web 123 The speed W2 can vary between about 5.025 fpm (about 1.532 m / min) to about 525 fpm (about 160.02 m / min) as long as W2 / W1> 1.

In one embodiment, the width of cathode web 23 varies between about 0.75 inches (about 1.905 cm) and about 24 inches (about 60.96 cm). The width of the anode web 123 can also vary between about 0.75 inches (about 1.905 cm) and about 24 inches (about 60.96 cm). The length of each cathode sheet 52 can vary between about 0.25 inches (about 0.635 cm) and about 24 inches (about 60.96 cm). The space 53 formed between adjacent cathode sheets may be between about 0.015 inch (about 0.038 cm) and about 0.4 inch (about 1.016 cm). In embodiments in which a lamination offset is formed between cathode web 23 and anode web 123 during the lamination process, such lamination offset may vary between about 0.04 inch (about 0.102 cm) and about 0.31 inch (about 0.787 cm). Can be.

For purposes of illustration and not limitation, examples are provided for the parameters of the rotation conversion process. In this embodiment, the cathode web 23 is considered to move at a speed W1 of 50 fpm (about 15.24 m / min). The speed W2 of the anode web 123 is 51 fpm (about 15.545 m / min), thereby providing a speed ratio of W1 to W2 of about 1.02. Each cut cathode sheet is 3.92 inches (about 9.957 cm) in length. The space 53 between adjacent cathode sheets 52 is 0.08 inches (about 0.203 cm). The spacing between cutouts cut through only the portion 54 of the anode of the web (the anode carriage 51 is not penetrated) is 4.0 inches (about 10.16 cm). The anode and cathode webs are 5.63 inches (about 14.30 cm) wide, respectively. According to this embodiment, the stacking offset is 0.24 inches (about 0.61 cm).

3C-3F illustrate some rotational conversion device configurations that may be implemented differently than described above with respect to FIGS. 3A and 3B. 3C-3F show four useful configurations with different process speed relationships in three parts of the rotational converter. In particular, the velocity associated with the feed 32 ', the cut 34' and the stack 36 'is represented by the velocity WX (where X is 1, 2 or 3). In general, the relationship between the speed W1, the speed W2 and the speed W3 has the characteristics W1 ≦ W2 ≦ W3, but it is not necessarily so.

In Fig. 3C, for example, the speeds associated with each of the supply portion 32 ', the cut portion 34' and the stacked portion 36 'according to this rotation converter configuration are given by W1, W2 and W2, respectively. In this case having a configuration substantially the same as that described above with respect to Figs. 3A and 3B, W1 is smaller than W2.

FIG. 3D shows another rotational converter configuration, in which the velocities associated with each of the feed 32 ', cut 34' and stack 36 'are all substantially the same (speed W1 in this embodiment). Is the same). 3d further includes a take-up roll 27 for winding the liner at speed W1. This configuration is well suited for use with rotating dies having a pattern such as a rotating die comprising rectangular die blades. According to this configuration, the rectangular die blade cuts the rectangular cut into web structures (eg, cathode stacked structures) in which gaps are formed between adjacent web structures upon removal. Excess or waste web matrix material may be rewound on a liner moving at a speed W1 by the winding roll 27.

Laminating the web structure sheet passing through cut 34 'at speed W1 to another web 123, such as the web of the anode stack, may also be made at speed W1 at stack 36'. have. Preferably, the rotation converter arrangement shown in FIG. 3D provides a desired gap between adjacent cathode stack structures while maintaining a substantially constant process speed at each feed, cut and stack 32 ', 34' and 36 '. Form.

3E illustrates another rotational converter configuration, where the speeds associated with the feed 32 'and cut 34' are substantially the same, and the stack speed is W2. In this configuration, the conveyor 25 is disposed between the cut portion 34 'and the stack 36'. The speed of the conveyor 25 is substantially the same as the speed of the stack 36 '(ie W2).

Fig. 3f shows another rotational converter arrangement, where the speeds associated with the feed 32 ', the cut 34' and the stack 36 'differ from each other. In this particular embodiment, the speeds associated with the feed 32 ', cut 34', and stack 36 'are denoted by W1, W2, W3, respectively. The conveyor 25 disposed between the cutout 34 'and the stack 36' moves substantially at the same speed (ie, W3) as the stack 36 '.

It can be seen that the configuration of each rotation converter shown in FIGS. 3A-3F provides a predetermined gap between adjacent web structures or sheets. The gap size or spacing between adjacent web structures / sheets may be varied by appropriate choice of die blade size, configuration and spacing, and / or process speed (eg, speeds W1, W2, W3). As is evident from the description below, the gap formed between adjacent web structures / sheets facilitates the processing of the laminated article (eg, laminated unit cell) at the second cutting station.

Another stacking device “pick and place” is used to transport each web structure cut from the web to the second web 123 at the cut 34 ′ for lamination to the second web 123. It will be understood by those skilled in the art that this may be the case. According to this another method, the stack 36 'will be replaced or reconfigured with the stacking device of choice.

4 shows the second cutting station 40 shown in FIGS. 1 and 2 in more detail. As shown in FIG. 4, the laminated web 50 is shown as a series of spaced cathode sheets 52 laminated to an anode web 123 having a release liner 51. Lamination web 50 moves to the second cutting station at speed W2. The rotating die 44 and the anvil 45 of the cutting roll device 41 are typically moved at the same speed W3 as W2 (but can vary to strike the space 53 consistently). For example, the speed W3 may vary between about 50 fpm (about 15.24 m / min) and about 55 fpm (about 16.764 m / min). The diameter of the rotating die 44, the spacing between the die blades 48, and the speeds W2 and W3 are stacked only within the space 53 between the individual cathode sheets 52 to which each die blade 48 is adjacent. It is suitably selected to rotate in cut engagement with the web 50. A detailed illustration of the cutting roll device 41 in zone "A" of FIG. 4 is provided in FIG.

FIG. 5 shows a portion of the laminated web 50 in the rotational cutting contact area defined between the rotating die 44 and the anvil 45. It is shown that the die blade 48 of the rotating die 44 cuts through the anode web material 54 in the space 53 formed between the adjacent individual cathode sheets 52. The die blade 48 is cut through the anode material layer 54 completely, but the release liner 51 is only partially penetrated. It should be noted that the release liner 51 may hardly be cut by precisely controlled cutting.

As described above, a series of stacked unit cell sheets supported on a release liner at the exit of the second cutting station 40 shown in FIG. 4 is produced. The stacked unit cell sheets may be wound on a take-up roll for later processing by the stacking device or transferred directly to a stacking device that is part of a continuous rotation conversion / loading operation.

The configuration of the anode web 123 and the cathode web 23 as described above may vary depending on the material, the number of material layers, and the alignment, size and shape of such material layers. For example, cathode web 23 may be comprised of aluminum foil having a cathode coating on both sides. In this example, the anode web 123 may be comprised of polyethylene / SPE / lithium foil / SPE, where the SPE is a solid polymer electrolyte.

As another example, cathode web 23 may be comprised of a cathode / carbon coated aluminum foil / cathode. In this example, the anode web 123 may be composed of polyethylene / SPE / lithium foil / SPE.

The rotation converter and method of the present invention can be used to laminate various sheet materials, and is not limited to thin film electrochemical cells only. In addition, the rotary lamination process does not necessarily have to form a space between the web material sheets processed by the first cutting station 28, but such space is desirable for certain applications (eg, manufacturing thin film electrochemical cells). I do.

The stacking device and method of the present invention provide for continuous stacking of stacked articles of various types, sizes and shapes, for example by using a rotating stack contact area. Generally, a series of flat pucks, pallets or carriages are transported continuously through the nip to build up an accurate stacked stack of sheet shaped products on top of the puck. The product sheets are continuously moved from the peelable web liner to the puck in a continuous or alternating manner to form a stack of product sheets at a predetermined height. Several embodiments of the loading apparatus and method are described below, and these embodiments are generally classified into "DL" (Direct Lamination) or "VL" (Vacuum Lamination) devices and methods.

According to the DL method, the product sheets are transferred directly from the release web liner to the puck in a direct lamination method. According to the VL method, the product sheets are first transferred from the release liner to the vacuum roll and then laminated to the puck by the indirect lamination method. Either side of the product sheets may be tacky. In addition, non-adhesive forms of loading may also be achieved, for example by using hook-loop, electrostatic, magnetic or mechanical gripper mechanisms. According to the present invention's rotational lamination process for assembling the material layers (the two embodiments are DL and VL methods), air is preferably removed in the lamination structure.

The product fed to the lamination process may be in the form of a tape on a release liner. A cut of a predetermined depth on the product formed up to the liner separates the product into individual product sheets. In one method, there is no space between adjacent product sheets. This reduces waste compared to traditional labeling methods where weeds are removed. The loading process may be designed to accommodate the accumulation of small deviations in product sheet length and the lack of space between adjacent product sheets. Alternatively, as described above, a space may be formed between at least some layers of adjacent multilayer product sheets.

Referring now to FIG. 6, a VL stacking device 120 is shown for continuously manufacturing a stack of product sheets in accordance with one embodiment of the present invention. According to this embodiment, the product web 135 supplied to the VL stacking device 120 can be manufactured by the upstream rotational conversion device 20 as described above. Alternatively, product web 135 may be provided by a proprietary feed roll. The product web 135 is a single product sheet or package (e.g. electrochemical) that is releasably attached to the release liner of the product web 135 as manufactured by the second cutting station 40 described above. Unit cell).

According to the VL loading process shown in FIG. 6, a laminated nip 147 is formed between each of the series of moving puck 142 and the vacuum roll 130. Preferably, a single product sheet or package containing a tacky material on one side is conveyed to the nip 147 via the vacuum roll 130 with the adhesive side out.

The product sheets are spaced on the vacuum roll 130 to facilitate machining timing. The product sheets are received on the vacuum roll 130 as the release liner of the product web 135 is peeled off at the peeling point of the small radius formed in the contact area between the vacuum roll 130 and the stripper roll 134. do. In the stripper roll 134, the product sheets are transported over the vacuum roll 130 while being spaced apart from the release liner. The release liner is transferred to the take-up roll 124.

At the six o'clock position on the vacuum roll 130, the product sheets are separated from the vacuum roll 130 and stacked on a puck 142, generally shown as a rectangle in FIG. 6. 6 shows a web path (web path 1) shown to be loosened towards the vacuum pull roll 130. This web path can be used to separate the loading device 120 from the rotation converter 20. For example, the laminated web manufactured at the exit of the rotation converter 20 may be wound one day and unwound and processed by the loading device 120 the next day.

According to one embodiment, the puck 142 is sent to the nip 147 by a timing belt or chain driven conveyor 202 in a continuous circulation method. In this particular embodiment (see also FIG. 8), the spaced pucks 142 traverse the top of the conveyor 202 in a predetermined direction and along an arc path along one side of the conveyor 202, After passing through the bottom of the conveyor 202, it returns to the top of the conveyor 202 along an arc path along the other side of the conveyor 202. The puck 142 may move along a continuous path on the conveyor 202, or may follow the continuous path by using a reciprocating conveyor according to another method.

One or more VL stacking devices 120 may be used to continuously manufacture a stack of product sheets. For example, in the case of using two VL stacking devices 120, each stacking device 120 may stack the same or different layers of material on the puck 142 with the same or different size / shape.                 

In another embodiment, as shown in detail in FIGS. 7A and 7B, the puck 142 is sent to the nip 147 shown in FIG. 6 through the reciprocating conveyor 146a in a continuous circulation manner. In this embodiment, a pair of reciprocating linear motors 150a and 150b operate below the plane of the puck 142. While the first motor 150a drives the puck 142 toward the nip 147, the second motor 150b is waiting.

The first motor 150a adjusts the speed and position of the leading puck 142 before entering the nip 147. When the leading puck 142 enters the nip 147, the first motor 150a peels off and makes a quick and empty return trip to engage subsequent second puck 142 in line. To engage the second puck 142, the first motor 150a matches the speed and position with the moving puck 142 (ie, the puck 142 one length behind the first puck in line). The gripper 156 is operated to hold a gripper hold protruding from the bottom of the puck 142.

Puck 142 exiting nip 147 is pushed out of the conveyor loop to return to the end of the line. This puck 142 lies on the bottom flat side of the reciprocating conveyor 146a. For example, in the transition from the final conveyor to the rail or bearing portion by the linear bearing guide 154, a positional tolerance is necessary to be able to engage the linear bearing guide 154. Once mounted on the linear bearing guide 154, the puck 142 is automatically aligned.

The linear linear motors 150a and 150b and the gripper 156 move reciprocally, while the puck 142 moves continuously. A speed of about 300 laminations per minute can be realized by a motor acceleration of about 40 m / s ² . This level of productivity can be achieved using commercially available components. This evaluation is based on the puck 142 having a length of about 100 mm, which provides a nominal line speed of about 30 meters per minute.

As also shown in FIG. 6, optical sensors 138 and 133 detect the product sheet on puck 142 and vacuum roll 130 as needed. In general, linear motors 150a and 150b use linear encoders for position feedback.

Within the background of the wider process, the filled puck 142 is sent to the finishing station, while the empty puck 142 is inserted into the load loop. For example, a relatively high nip pressure may be required to accurately form certain types of products such as batteries or fuel cells. Medical products and packaging applications may not require such high forces. The embodiments shown in FIGS. 7A and 7B are designed to provide good mechanical support under pressure of the nip 147 where the total force may be greater than 600 pounds (about 272.155 kg).

As shown in Figs. 7A and 7B, the puck 142 continuously moves from right to left. The puck 142 in the nip 147 is supported on a roundway bearing and rail or on a cam follower that slides in a machined groove. None of these allow the puck 142 to be transferred between the conveyor 146a and the linear bearing guide 154. These bearings or cam followers may be implemented independently of the linear motor bearings and thus may have the size necessary to withstand the laminated load. The bearing or cam follower may move with the puck 142 or may be stationary arranged to form a “active” track for the puck 142.

In front of the rail / guide portion or lamination table 145 the conveyor 146a moves the entire row of puck 142 in the advancing direction at nominal line speed. Vertical control of the nip 147 may be through a vacuum roll. Vertical control is needed to accommodate the increase in height of the package or product on the puck 142. The top of the puck 142 or the vacuum roll 130 itself may be coated with a soft material.

In the configuration using the linear motors 150a and 150b, the linear bearing guide 154 supports an independent bearing that supports both the coil and the gripper 156. If the linear bearing guide 154 is strong enough to support the stacking force, the cam follower and the machined groove may not be necessary. In this case, the gripper 156 will carry the puck 142 completely through the nip 147, which makes the trajectory somewhat longer.

In yet other embodiments, the vacuum roll 130 may not be used. The puck 142 is sent directly under the peeling station, or directly to another sheet feed mechanism, where the leading end of the product sheet engages the leading end of the stack. This method is similar to the method used in labeling machines. The puck can then be moved through the nip to complete the lamination.

8 illustrates an embodiment of a direct lamination apparatus 190 for transferring a product sheet from a peelable web liner to a puck 142 in a direct lamination method. The direct lamination apparatus 190 shown in FIG. 8 includes a conveyor 202, around which a plurality of puck or carriage 142 is circulated.

In this particular embodiment, the spaced pucks 142 traverse the top of the conveyor 202 in a predetermined direction and pass along the bottom of the conveyor 202 along an arc path along one side of the conveyor 202. Then, it returns to the top of the conveyor 202 along an arc path along the other side of the conveyor 202. The puck 142 may move along a continuous path on the conveyor 202 in the manner described above with respect to the VL method. In addition, the DL method may selectively use the above-mentioned reciprocating conveyor.

As shown in FIG. 8, a nip 214 is formed between each puck 142 and lamination roll 212 as the puck 142 moves close to the lamination roll 212. In this embodiment, the product web 213 is released from the supply roll 210 and formed between each puck 142 and the lamination roll 212 when the puck 142 moves close to the lamination roll 212. Sent to nip 214. One or more support rollers 201 may be disposed on the conveyor 202 to provide a relatively high lamination force formed between the lamination roll 212 and the puck 142.

As each puck 142 passes close to the lamination roll 212 to form the nip 214, a product sheet 216, such as an electrochemical unit cell sheet, is transferred from the web to the puck 142. The puck 142 moves along the conveyor away from the lamination roll 212, and the next puck 142 moves proximate the lamination roll 212 to form the nip 214. The product sheet 216 is conveyed from the web to the puck 142. This process is repeated a number of times to build up a stack of product sheets on each puck 142 reciprocating under the lamination roll 212. Nip 214 is vertically controlled to accommodate an increase in the height of the package or product on puck 142.

It is preferred, but not necessary, for the puck 142 to be secured to the conveyor 202 (or moving above the conveyor 202) to have a length greater than the length of one product sheet / stack. In one embodiment, the length of the puck 142 is about 4 inches (about 10.16 cm) (eg, 4.09 inches (about 10.389 cm)) and the width of the puck 142 is about 6 inches (about 15.24 cm). ), For example, 5.91 inches (about 15.011 cm). The spacing between the individual pucks 142 is approximately equal to one product sheet / stack length.

According to one embodiment, the product web 213 may move at a speed between 0 and 10 meters / minute. The product web width may be about 8 inches (about 20.32 cm). The product sheets may be electrochemical unit cell sheets having a length up to about 17 inches (about 43.18 cm).

In the embodiment shown in Fig. 8, only one stacking station is used. Thus, the product sheets detachably attached to the web are filtered out one by one to the puck 142 and the remaining product sheets remain attached to the web. These unused product sheets can be wound up with a liner during the first pass through the DL device 190 and 100% utilized by a second pass to transfer the remaining product sheet to each puck 142.

The adhesion of the non-adhesive portion of the top of the first product sheet layer laminated to the puck 142 and the non-adhesive portion of the product sheet should be high enough to facilitate the grabbing of the product sheet from the release liner of the web. The adhesion of the bottom of the first layer to the top of the puck 142 is high enough to secure the stack for the remainder of the process but should be easily peelable if necessary. In the case of an electrochemical cell structure, for example, the first layer may be a tacky electrolyte / lithium foil / adhesive electrolyte structure, and the top of the puck 142 may comprise a thin layer of inert peelable dielectric material. . In this case, each subsequent layer generally has a cathode / current collector / cathode / electrolyte / lithium foil / electrolyte structure.

In one embodiment, the adhesion of the product sheet to the release liner of the web generally ranges from about 2 grams / inch to about 100 grams / inch. The adhesion of the product sheet to the product sheet generally ranges from about 300 grams / inch to about 1200 grams / inch.

Due to the difference between the first and subsequent layers in the DL stacking process, a roll change or splice may be needed after all puck 142 has first noticed nip 214. After the product stack is complete, the puck 142 is emptied. This can be done easily using the automatic unloading method or manually. Separating the product stack from the puck 142 may be realized, for example, by using a peelable adhesive such as a thin layer of inert peelable dielectric material described above between the puck surface and the adjacent product stack layer. According to another embodiment, a vacuum mechanism that may be used to secure the product stack to the puck surface during the loading process may be operated to create back pressure on the product stack to facilitate unloading of the product stack from the puck.

According to one embodiment, the lamination roll 212 is coated with rubber. The puck 142 is basically flat and hard. Since the rubber coated lamination roll 212 deforms in the nip 214, the product stack remains substantially flat and relatively unstressed, which is generally desirable. The coating provided on top of the puck 142 may be thin enough to allow heat transfer from the shorted cell to the puck 142, which has the advantage of being safe in the event of such a short. Also in this embodiment, since the release liner does not bend around the release point, the liner can be reused to reduce costs. In addition, the product sheets do not deviate well from the aligned (or mated) state because the product sheets always reliably contact one or both of the puck 142 or web liner. In addition, according to this embodiment, no vacuum roller is required, which further reduces costs.

 Preferably, the puck sensor and product sensors are used to adjust the position of the DL lamination roll 212 to accommodate the increasing height of the stack and to maintain the registration of the product sheet on the puck 142. These sensors facilitate fine adjustment of the position and speed of the chain drive, thus facilitating fine adjustment of the position and speed of the puck 142 relative to the product seat attached to the web. A timing belt or other servo system may be used instead of the chain driven conveyor 202, and the puck 142 need not necessarily be secured to the conveyor 202.

9 illustrates a DL device 200 comprising two stacking stations 202 and 204 in accordance with another embodiment of the present invention (eg, a single product web, a dual stacking station). 9 shows a DL process proceeding from left to right. Each of the two stacking stations 202 and 204 alternately stacks the product sheet 216 transferred from the carriage web 213 to a set of reciprocating pucks 142. More specifically, the first lamination station 202 filters the product sheet to its respective puck 142 while the second lamination station 204 transfers the remaining product sheet to its respective puck 142. Transfer. In the embodiment shown in Fig. 9, each of the stacking stations 202, 204 includes chain driven conveyors 146b, 146c.

The carriage web 213 of the product sheet 216 is unwound from the feed roll 210. The carriage web 213 of the cut product sheet 216 may be manufactured using a rotation converter and method as described above. The carriage web 213 continuously passes through the nip 214 formed between each puck 142 and the first lamination roll 212 at the first lamination station 202. Because of the spacing provided between the pucks 142 moving over the conveyor 146b of the first lamination station 202, the carriage web 213 is released from the feed roll 210 and on the take-up roll 222 during the DL process. As it is rolled up, the product sheet 216 is transferred every other from the carriage web 213 to the puck 142.

At the second lamination station 204 a second nip 215 is formed between each puck 142 and the second lamination roll 220 reciprocating around the conveyor 146c. After passing through the first lamination station 202, the remaining product sheet 216 is transferred from the product web 213 to the puck 142 of the second lamination station 204 on the carriage web 213. Thus, a stack of product sheets is formed on the puck at each of the two stacking stations during a continuous DL process. It should be noted that the product sheet 216 releasably attached to the carriage web 213 may be disposed above the carriage web 213 with or without gaps between adjacent product sheets 216.

It will be appreciated that more than one lamination station may be used and process parameters such as web speed, product sheet size and puck spacing may be appropriately adjusted to facilitate addition of lamination station. Preferably, a puck sensor and a product sensor are used to maintain registration of the product sheet on the puck 142. These sensors independently facilitate the fine adjustment of the speed and position of the conveyors 146b and 146c (eg chain drives). Timing belts or other servo systems may optionally be used in place of chain driven conveyors 146b and 146c.

10 illustrates a DL device 201 according to another embodiment of the present invention. This embodiment is an example of a dual lamination station-single conveyor DL device. As shown, the DL device 201 includes a single stacking station 203 that includes a conveyor 221. The web 213 of the product sheet 216 is released from the feed roll 210 and passes between the first lamination roll 212 and the series of reciprocating pucks 142. The alternating product sheet 216 is transferred every other from the web 213 to the moving puck 142 at the first nip 214. The remaining product sheet 216 is conveyed to the moving puck 142 at the second nip 215 formed between the second lamination roll 220 and each puck 142. The release liner is then wound on the winding roll 222.

According to the DL method using the apparatus 201 shown in FIG. 10, the carriage web 213 is a pre-cut with alternating sheets of cathode / current collector / cathode structure and separator / anode / separator structure in one stack. The electrochemical unit cell sheet 216 is a release liner supported to be peelable. Optionally, the carriage web 213 may support a precut electrochemical unit cell sheet 216 in which the separator / anode / separator structure and the cathode / current collector / cathode structure alternately bond the sheets in one stack. have.

According to one embodiment, the product web 213 may move at a speed between 0 and 10 meters / minute. The width of the product web may be about 8 inches (about 20.32 cm). The unit cell sheet may have a length of up to about 17 inches (about 43.18 cm).

FIG. 10 also shows some additional components that may be used in other embodiments as shown in FIGS. 8 and 9 above. The DL device 201 may include a web guide 223 to assist web alignment as the web passes over the tension roll 219. An infrared heater 232 may be used to heat the product sheet 216 to a predetermined temperature. An alignment sensor 234, such as an optical sensor, may be used to detect the position and speed of the chain drive / conveyor 221 and / or the puck 142 and the position of the product sheet 216 on the carriage web 213. . The conveyor 221 may include one or more servo controlled drive rollers 211 to facilitate adjustment of the conveyor speed during the DL process. As in other embodiments, the lamination rolls 214, 215 are vertically controlled to accommodate the increase in height of the package or product on the puck 142. Alternatively, the cell height can be adjusted by adjusting the height of the puck.

11 illustrates another embodiment of a DL device 300 in accordance with the principles of the present invention. According to this embodiment, multiple product webs 306, 322 pass through multiple laminated nips 214, 215, respectively, thereby stacking a stack of package or sheet products on a series of continuously moving reciprocating pucks 142. Configure. As shown, the product web 306 includes a different product sheet than the product sheet removably attached to the product web 326, but the two product webs 306, 326 may support the same type of product sheet. It may be. As also shown, each product web 306, 326 has only one associated laminated nip 214, 215 such that the product sheets are filtered one by one to each puck (214, 215) in each nip 214, 215. 142). Two laminated nips may be provided for each product web 306, 326 such that all product sheets of a given web may be transferred to each puck during a single pass. In addition, two or more laminated nips may be provided for each product web 306, 326 such that all product sheets of a given web may be transferred to each puck during a single pass.

An advantage of implementing the DL method according to this embodiment is that it is possible to alternately stack each product sheet supported on the webs 306 and 326 irrespective of whether the product sheet is first transferred to the puck 142. Is there. For example, product web 306 may releasably support an electrochemical anode product sheet comprising a separator / lithium foil / separator structure. The product web 326 may releasably support an electrochemical cathode product sheet comprising a cathode / current collector / cathode structure. For example, the anode product sheet may be laminated first to the puck 142 and then the cathode product sheet may be laminated to constitute an alternate stack of anode / cathode product sheets.

According to one embodiment, product web 306 may move at a speed between 0 and 10 meters / minute. The width of the product web may be about 8 inches (about 20.32 cm). The unit cell sheet may have a length of up to about 17 inches (about 43.18 cm). Product web feed rolls 302 and 322 may each have a diameter of up to about 18 inches (about 45.72 cm).

Referring now to Figures 12A and 12B, a stacking / laminating apparatus 500 in accordance with another embodiment of the present invention is illustrated. According to this embodiment, the loading / laminating apparatus 500 may be used to make a stacked stack of materials with high precision. The material processed by the stacking / lamination apparatus 500 may include layers of materials having different sizes and ductility.

According to the embodiment shown in Figs. 12A and 12B, the puck does not need to move while the product sheet is being transferred from the lamination roll to the puck. The puck may or may not be attached to the conveyor, but in this embodiment the conveyor does not need to be moved during the lamination or stack forming process. The roller is moved across the puck and rotates simultaneously between position A and position B so that a point on the surface of the roller contacts the puck at the same position of each pass. The roll can hold the divided product sheet in a fixed position on the surface of this roll. This may be realized by vacuum, electrostatic or adhesive.

The loading / laminating device 500 has an adjustable mechanism that controls the distance from the surface of the puck to the surface of the lamination roll. As the stack height increases, the distance increases. The roll may convey the divided product sheet or the divided product sheet supported by the liner sheet to the puck. The stacking / laminating device 500 is designed to precisely align two different stacks or stacked composites into one stack. A pallet of each stack may be attached to one end of the machine for pickup of the stack prior to stacking.

According to one embodiment, the loading / laminating apparatus 500 utilizes a vacuum roll 502 to position and secure the material. Positioning of the material is made using a reference mark on the vacuum roll 502. After a piece of material is placed on the vacuum roll 502 using a roll reference mark for correct placement, the vacuum roll 502 is driven by rotating it with the handle 504. The vacuum roll 502 advances over the device 506 for position matching in rotation.

Due to this interaction, the piece of material carried by the vacuum roll 502 is always provided at the same location on the lamination puck 508, where lamination takes place. Since the piece of material adheres to the lamination puck 508 or a subsequent layer of material with a force greater than the holding force of the vacuum roll 502, the piece of material is separated from the vacuum roll 502 and transferred to the lamination puck 508. A second layer of material is then placed on the vacuum roll 502 according to another set of reference marks on the vacuum roll 502, which reference marks depend on the appropriate lamination requirements for a given process. Stacked in reverse on an increasing stack of material. As the stack increases, screw jack 510 is actuated through handle 513 to lower the stack stack height and maintain a constant stack pressure for tolerance.

In addition, the stacking / laminating apparatus 500 includes a station 501 having an adjustable table 505 and a station stacking opening 503. The adjustable table 505 with the top surface 507 may be adjusted with respect to vertical (eg height), transverse, axial axes (eg x, y, z axes) and further It can also be adjusted for yaw. The adjustable table 505 may be disposed within this station 501 integrally with the station 501, and may be disposed below the station stacking opening 503 of the station 501. The apparatus further includes a puck 508 attached to the top surface 507 of the adjustable table. Puck 508 is movable relative to the adjustable table top movement. A rotatable stacking surface 502 is provided for movement between position A and position B, and includes an apparatus 506 for matching the position of the puck 508 to the rotatable stacking surface 502. do.

According to this embodiment, the first product conveying device supplies a first product sheet, such as a cathode laminate structure, to the rotatable laminate surface 502. The second product conveying device supplies a second product sheet, such as an anode laminate structure, to the rotatable laminate surface 502. The first and second product conveying devices cooperate with the rotatable stacking surface 502 to repeatedly and alternately transport each of the first and second sheets from both ends of the station 501 to the puck 508. This produces a stack in which alternating first and second product sheets are alternately stacked on puck 508.

The sheets may be retained at the rotatable laminate surface 502 by using vacuum, adhesive, static electricity or a combination of these methods. According to one method, matching the position of the stacking puck 508 to the rotatable stacking surface 502 is realized using the rack and pinion device 506. For example, other position matching or adjustment mechanisms may be used, such as roller bearings with guide rollers, devices for selection and placement or other gear / belt assemblies.                 

The movement of the top surface 507 and the rotatable stacking surface 502 of the adjustable table may be made manually. Optionally, the movement of the top surface 507 and the rotatable stacking surface 502 of the adjustable table may be performed in a fully or partially automated manner using one or more controllable electric motors or the like.

In one embodiment, all or part of the puck 508 is formed from thermally and electrically insulating materials. The puck 508 may include position indicators, such as, for example, x, y, z position indicators and yaw indicators. The product conveying device may comprise one or more webs of single or multilayer sheets, and the sheets may comprise a release liner. The product conveying apparatus may include one or more manual sheet feeding apparatus for manually feeding the sheet to the rotatable laminated surface 502.

It will be appreciated that a wide variety of materials of various types, sizes and shapes may be processed by rotation conversion and / or loading devices and methods in accordance with the principles of the present invention. The principles of the present invention may be applied, for example, to the construction of a stacked fuel cell.

According to one embodiment, electrochemical devices including proton exchange membrane fuel cells, sensors, electrolyzers, chloride-alkali separation membranes, and the like may be constructed from membrane electrode assemblies (MEAs). Such membrane electrode assembly engages at least one electrode portion comprising an electrolyte electrode material such as platinum (Pt) in contact with the ion conductive membrane. Ion conductive membranes (ICMs) are often used in electrochemical cells such as solid electrolytes.

In a typical fuel cell, for example, an ion conductive membrane (ICM) contacts the cathode and the anode and transports ions formed at the anode to the cathode, allowing current to flow in an external circuit connecting the electrodes. The central component of an electrochemical cell such as a fuel cell, sensor, electrolyzer or electrochemical reactor is a three layer membrane electrode assembly or membrane electrode assembly (MEA). Membrane electrode assemblies (MEA) most commonly comprise two catalytic electrodes, between which an ion conducting electrolyte, preferably a solid polymer electrolyte, is inserted. Eventually, this three layer MEA is inserted between two porous electrically conductive elements (called electrode baking layers (EBLs)) to form a five layer MEA.

The apparatus and method of the present invention combine, for example, a three-layer MEA to each cathode and anode side EBLs to couple the cathode and the anode to the ICM in a mated state and to form a five-layer MEA in a subsequent step. Can be used to Alternatively, the preformed subassemblies of the five layer MEA can be combined with each other to form a finished MEA. For example, a subassembly comprising an EBL to which an electrode layer is coupled may be coupled to a subassembly comprising an EBL to which a second electrode supporting an ICM is coupled.

Other kinds of stacked stacks may be made according to the principles of the present invention. Figures 13-18 illustrate some other kinds of stacked stacks that can be fabricated using the rotational transformation and / or VL / DL loading methods of the present invention.

Figure 13 illustrates a lamination stack of multicolor sheet material. Multi-layered or printed sheets can be stacked together, cut into desired shapes, and then stacked. For example, five different product webs, each having a unique color, with an adhesive on a portion of the back side, may be stacked together and cut into a predetermined shape. This stack may be placed on a recirculating puck until a number of stacks have been stacked, and when the stacks are stacked, each puck is removed from the recycle loop and replaced by an empty puck.

Figure 14 shows a multilayer of paper or film of monochrome sheet with a portion of the back side having an adhesive, these layers being stacked together and cut into desired shapes at a first cutting station (e.g., a rotating die station). The cut stack is placed on the puck. In the second web line, the multilayer of the second collar, with a portion of the back side having the adhesive, is stacked together and cut into the desired shape at the second cutting station. This cut stack is placed on the puck having the cut stack at the first cutting station.

This process may continue for a total of five independent web lines, for example. The puck moves from web line to web line in the order in which the stack is created. When one pad is completed, each puck is moved out of the loading device and replaced with an empty puck. The completed puck is transferred to a packout section.

FIG. 15 illustrates a product stack or pad similar to that shown in FIG. 14. The product stack shown in Figure 15 is oval shaped, while the product stack shown in Figure 14 has a square or rectangular shape. The shape of the product stack shown in Figures 14 and 15 may vary as needed.

Figure 16 illustrates another article stack or pad similar to that shown in Figures 14 and 15 but with layers of various shapes, and the color of the sheet (e.g. paper or film) may or may not change. . Figure 17 shows a product stack similar to that shown in Figures 14 and 15, but each sheet has a different shape and only one sheet is placed on this puck at a time. It may have multiple shapes, in which more than five independent cutting stations may be required.

Figure 18 illustrates a pack of medical dressings loaded in accordance with the principles of the present invention. The bottom web acts as the bottom sheet of the sterile package while also acting as a liner for the product. The adhesive with the pattern is coated onto the package web on the non-liner side. The medical dressing is moved upstream from this process, and each dressing is cut and placed over the liner / package web. This package web is cut and placed over the recirculating puck and another dressing on the package web is cut and placed on top of the stack. This process can be repeated for example between 10 and 50 times.

Once all the dressings are placed on the puck, the top package web is attached to the top of the stack, serving as the top film of the dressing on the top of the stack. To use the product, the upper web is removed, whereby the dressing is exposed. Once the dressing is removed, the bottom package web / product liner for the previous dressing is now the top package web for the next product.

The foregoing description of the various embodiments of the present invention is intended to be illustrative. The present invention is limited to these descriptions, or these descriptions do not all represent the present invention. Many modifications and variations can be made from the above description. It is intended that the scope of the invention be limited not by this detailed description, but rather by the claims appended hereto.

Claims (37)

A method of manufacturing a series of thin film electrochemical unit cells, Cutting a web (cathode web) comprising a cathode laminate structure moving at a first speed into a series of cathode sheets, Moving the respective cathode sheets at a second speed equal to or faster than a first speed, Heating either one or both of the anode web or cathode sheet, and comprising an anode laminate structure moving at a second speed to produce a stacked unit cell having a space between adjacent cathode sheets. Laminating each cathode sheet moving at a second speed to the web (anode web), Cutting the laminated anode web in the space between adjacent cathode sheets to produce a series of unit cell sheets. The method of claim 1, i. Cutting the cathode web includes cutting a portion of the cathode web and removing excess cathode web, wherein cutting the cathode web optionally includes rotatably cutting the cathode web; ii. Laminating each cathode sheet to the anode web further comprises rotatably moving the anode web at a second speed; iii. Laminating each cathode sheet to the anode web further comprises rotatably moving the anode web at a second speed while rotatably moving each cathode sheet at a second speed; iv. Each cathode sheet is defined by a length L between 0.25 inches (0.635 cm) and 24 inches (60.96 cm), v. The space S between adjacent cathode sheets is between 0.015 inches (0.038 cm) and 0.4 inches (1.016 cm), vi. The ratio of the second speed to the first speed is between 1.005 and 1.05, vii. The first speed is between 5 feet (1.524 m) per minute and 500 feet (152.4 m) per minute, the second speed is between 5.025 feet (1.532 m) per minute and 525 feet (160.02 m) per minute, viii. Laminating each cathode sheet to the anode web comprises placing each cathode sheet to the anode web such that a portion of each cathode sheet extends beyond at least one edge of the anode stack structure of the anode web to provide a stack offset therebetween. Further comprising laminating, ix. Cutting the stacked anode webs further comprises detecting spaces between adjacent cathode sheets further comprising at least one of the thin film electrochemical unit cells. delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete delete

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